JP2007216529A - Manufacturing method for skin-integrated foamed article having groove-form pattern - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily and favorably manufacture a skin-integrated foamed article having a groove-form pattern which is suitable for an instrument panel or the like. <P>SOLUTION: After arranging a skin 15 on the mold surface 32 of the lower mold 31 of a molding mold 30, a foaming material 19a is injected into the molding mold 30, and is made to foam. Thus, this skin-integrated foamed article for which the skin 15 and the foamed body have been integrated is manufactured. In this manufacturing method, a groove 16 having a bottom, which is indented from the front surface side to the rear surface side of the skin 15 is provided in advance on the skin 15. The molding mold 30 is provided with a sliding plate 33 which can protrude from and retract into the mold surface 32 where the groove 16 is arranged of the skin 15. The foaming of the foaming material 19a is advanced in a state with the sliding plate 33 inserted in the groove 16 of the skin 15, and the sliding plate 33 is retracted and removed from the groove 16 of the skin 15 before the completion of the foaming. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a skin-integrated foamed product having a groove pattern.

  Conventionally, as a method for producing a foam integrated foam product in which a foam is covered with a skin, the skin and foam are integrated by placing the skin on the mold surface and injecting the foaming raw material into the mold to cause foaming. The skin-integrated foaming method is often used.

  In recent years, for example, in the case of a foam integrated product for automobile interior parts such as an instrument panel, a product having a groove-like pattern on the surface has been demanded in order to improve decorativeness. Moreover, the groove-shaped pattern is required to be relatively thin with a width in the vicinity of the bottom of the groove of about 0.5 to 0.8 mm in order to further improve the decorativeness, and further, as shown in FIG. As described above, it is desirable to have a ridge pattern 17 that intersects the length direction of the groove at both ends of the groove 16.

  However, in the conventional method for producing a skin-integrated foam product, even if a groove is provided in advance in the skin, the groove is easily crushed or distorted by the foaming pressure of the foaming raw material, and a good groove-like pattern is obtained. It was difficult to form on the surface. Furthermore, it is difficult to make the groove narrow or to form stable ridge patterns on both ends of the groove.

Japanese Patent Laid-Open No. 7-60762 Japanese Patent Laid-Open No. 10-146841

  This invention is made | formed in view of the said point, Comprising: The manufacturing method of the skin integrated foam product which can obtain the skin integrated foam product which has a groove-like pattern easily and favorably is provided.

  The invention of claim 1 is a method for producing a foam integrated with a skin by disposing a skin on a mold surface of a molding die, and injecting a foaming raw material into the molding die to cause foaming. A groove with a bottom that is recessed from the back side to the back surface is provided in advance, and the molding die is provided with a slide plate that can protrude and retract from the mold surface on which the skin groove is disposed, and the slide plate is formed into the skin groove. A method of manufacturing a foam integrated foam having a groove-like pattern, wherein foaming of the foaming raw material is advanced in the inserted state, and the slide plate is retracted and extracted from the groove of the skin before completion of foaming. Related.

  According to a second aspect of the present invention, in the first aspect, before the foaming is completed, the slide plate is retracted and pulled out from the groove of the skin, so that the groove of the skin is pressed by the foaming pressure of the foaming raw material. It is characterized by narrowing the width.

  According to a third aspect of the present invention, in the first or second aspect, when the slide plate is inserted into the groove of the skin, a gap is formed between the tip of the slide plate and the bottom of the groove of the skin, The gap between the slide plate and the inner surface of the skin is made smaller at both ends than the center in the length direction of the slide plate.

  According to the first aspect of the present invention, foaming of the foaming raw material proceeds in a state where the slide plate is inserted into the skin groove, so that the foaming raw material is foamed by holding the skin groove in the mold correctly without falling down. A skin-integrated foam product having a good groove pattern on the surface can be obtained.

  According to the invention of claim 2, since the slide plate is retracted before the completion of foaming and extracted from the groove of the skin, the groove width is reduced by pressing the groove of the skin with the foaming pressure of the foaming raw material, A surface-integrated foamed product having a thin groove-like pattern on the surface can be easily obtained.

  According to the invention of claim 3, since the gap is formed between the tip of the slide plate and the bottom of the groove of the skin when the slide plate is inserted into the groove of the skin, The bottom of the skin groove can be made narrower by pressure. Moreover, since the gap between the slide plate and the inner surface of the groove of the skin is smaller at both ends than the center in the length direction of the slide plate, the skin groove is irregular at both ends of the groove when foaming raw material is foamed. Deformation (twisting, etc.) is less likely to occur, and a narrow groove-like pattern having a stable ridge pattern at both ends can be formed.

  Hereinafter, embodiments of the present invention will be described in detail. FIG. 1 is a perspective view showing an embodiment of an integrated foam body having a groove pattern on the surface produced by the production method of the present invention, and FIG. 2 is a cross-sectional view taken along lines AA and BB in FIG. 3 is a cross-sectional view of a mold used in an embodiment of the manufacturing method of the present invention, FIG. 4 is a partially enlarged cross-sectional view of FIG. 3, FIG. 5 is a cross-sectional view of FIG. FIG. 7 is a partially enlarged cross-sectional view of FIG. 6, FIG. 8 is a cross-sectional view taken along the line DD of FIG. 7, and FIG. FIG. 10 is a sectional view showing the foaming process in the same embodiment, FIG. 11 is a partially enlarged sectional view of FIG. 10, FIG. 12 is a sectional view taken along line E-E of FIG. 11, and FIG. FIG. 14 is a partially enlarged sectional view of FIG. 13, and FIG. 15 is a sectional view taken along line FF of FIG. It is.

  The skin-integrated foam 10 having a groove pattern on the surface shown in FIGS. 1 and 2 is used for an instrument panel of a vehicle. The skin-integrated foamed product 10 comprises a foam 19 formed between a base material 11 and a skin 15 and is obtained by a manufacturing method described later.

  The substrate 11 is made of a plastic having rigidity, such as ABS resin, and is formed into a predetermined shape by injection molding or the like. In addition, the said base material 11 may be made unnecessary depending on the use of a skin integrated foam product.

  The skin 15 is made of a flexible plastic and is formed in a predetermined shape by powder slush molding or the like. A bottomed groove 16 is formed at a predetermined portion on the surface of the skin 15, and the groove 16 forms a groove pattern. The groove 16 has a concave shape that is recessed from the front surface side to the back surface side of the skin 15, and a ridge pattern 17 that intersects the length direction L of the groove 16 is formed at both ends of the groove 16 on the surface of the skin 15. Yes. The dimension of the groove 16 is set to an appropriate value according to the required decorative property. For example, in the present embodiment, the width W1 of the groove 16 after foaming of the skin is 0.5 to 0.8 mm, the depth D1 of the groove 16 is 3 to 7 mm, and the length L1 of the groove 16 is 100 to 150 mm. Yes. The width W1 of the groove 16 after foam integrated with the skin is smaller than the width of the groove 16 formed when the skin 15 is formed, that is, the width of the groove 16 before the manufacture of the foam integrated with the skin. In this embodiment, as shown in FIGS. 4 and 5, the width W2 of the groove 16 of the skin 15 before foaming with the skin is 1.5 to 2 mm, the depth D2 is 3 to 7 mm, and the length L2 is 100 to 150 mm. Has been.

  Further, the bottom of the groove 15 of the skin 15 (the top of the groove in the state where the skin is arranged in the molding die when the skin is integrally foamed) 16a is located on the back side (skin of the skin) of the base 11 facing the portion 16a. A recess 12 that is recessed to the back side of the integral foam product is formed, and a gap for foaming raw material flow is secured between the bottom portion 16a of the groove 16 of the skin and the recess 12 of the base material 11 when manufacturing the below-described integral foam product. It is configured.

  The foam 19 is formed by foaming a foam raw material between the base material 11 and the skin 15 at the time of manufacturing a skin-integrated foam, which will be described later, and the base material depends on the adhesiveness of the foam at the time of foaming. 11 and the skin 15. The foam 19 is particularly preferably a polyurethane foam from the viewpoints of lightness, shock absorption, cost, and the like.

  The manufacturing method of the skin-integrated foam 10 having the groove pattern will be described. As shown in FIGS. 3 to 8, first, the base material 11 and the skin 15 are placed in a mold 30. When the skin-integrated foamed product does not require a base material as described above, the base material 11 is not used and is not disposed in the mold 30.

  The mold 30 includes a lower mold 31 and an upper mold 41. The mold surface 32 of the lower mold 31 and the mold surface 42 of the upper mold 41 are shaped according to the outer shape of the skin-integrated foam to be manufactured. Further, the skin 15 is arranged on the mold surface 32 of the lower mold 31 with the inner surface side (back surface side) facing the mold surface 42 of the upper mold 41, while the mold surface 42 of the upper mold 41 has The base material 11 is arranged toward the mold surface 32 of the lower mold 31. The base material 11 is detachably fixed to the mold surface 42 of the upper mold 41 by holding means such as a slide pin.

  The mold 30 is provided with a slide plate 33 that can protrude and retract from a mold surface 32 where the groove 16 of the skin 15 is disposed. The slide plate 33 of the present embodiment is provided at a position where the groove 16 of the skin 15 is disposed on the mold surface 32 of the lower mold 31, and is moved from the mold surface 32 of the lower mold 31 by an advance / retreat device 34 such as an air cylinder. The upper die 41 is configured to protrude and retract toward the die surface 42.

  The slide plate 33 is made smaller than the inner dimension of the groove 16 so that a protruding portion of the lower mold 31 from the mold surface 32 can be inserted into the groove 16 of the skin 15. In the present embodiment, the dimension of the slide plate 33 protruding from the mold surface 32 is such that the thickness F is 0.5 to 1.0 mm smaller than the width W2 of the groove 16, and the length G is the groove. The projection length H is set to be smaller by 0.3 to 1.0 mm than the depth D2 of the groove 16. In particular, the slide plate 33 has a substantially trapezoidal shape so that the amount of protrusion of the lower mold 31 from the mold surface 32 is smaller on both ends U2 side than the center U1 in the length direction U of the slide plate 33. The both ends U2 are composed of slopes. Reference numeral 33 a is the tip of the slide plate 33. The position and number of the grooves 16 provided in the skin 15 are not limited to those shown in the drawing, but are determined according to the shape of the skin-integrated foamed product, the required decorative properties, and the like. Further, the position and shape of the slide plate 33 are determined according to the position and number of the grooves 16.

  The slide plate 33 is inserted into the groove 16 of the skin 15 arranged on the mold surface of the lower mold 31 so that the groove 16 is correctly held in the mold 30. The slide plate 33 is inserted into the groove 16 when the slide plate 33 is previously projected from the mold surface 32 of the lower mold 31 and the skin 15 is placed on the mold surface 32 of the lower mold 31. The slide plate 33 protrudes from the mold surface 32 of the lower mold 31 by inserting the protruding portion of the slide plate 33 into the groove 16 of the skin 15 or after the skin 15 is disposed on the mold surface 32 of the lower mold 31. And inserting into the groove 16.

  Further, when the slide plate 33 is inserted into the groove 16 of the skin 15, a gap S is formed between the tip 33 a of the slide plate 33 and the inner surface of the groove 16 of the skin 15. The gap S is substantially trapezoidal in the shape of the slide plate 33, and the both ends U2 (in the illustrated example) are more than the gap S1 between the tip 33a and the bottom 16a of the groove 16 at the center U1 in the longitudinal direction U of the slide plate 33. The gap S2 in the slope portion) is reduced. In this embodiment, the gap S1 at the center U1 is 0.5 to 1.2 mm, and the gap S2 at both ends U2 (in the illustrated example, the slope portion) is 0.3 to 0.5 mm.

  After the skin 15 and the base material 11 are arranged on the molding die 30, the slide plate 33 is inserted into the groove 16 of the skin 15, and as shown in FIGS. A foam raw material 19a such as a polyurethane raw material is injected into the mold, and the mold is closed to cause foaming of the foam raw material 19a. The illustrated example is a so-called open injection type in which the foaming raw material 19a is injected while the molding die 30 is open and then closed, but a raw material inlet is formed in the molding die 30. A so-called closed injection type in which a foaming raw material is injected into the mold from the raw material inlet in a closed mold state may be used.

  The internal pressure of the mold 30 is increased by the foaming pressure due to the progress of foaming of the foaming raw material 19a, and the groove 16 of the skin 15 is pressed by the foaming pressure, but the groove 16 is correctly held by the slide plate 33. , Can prevent problems such as falling down. Further, as shown in FIG. 7, since the gap S1 is formed between the tip 33a of the slide plate and the bottom 16a of the groove 16 of the skin 15, the groove 16 is caused by the foaming pressure of the foaming raw material 19a. The bottom portion 16a can be made narrower. Further, the gap S between the inner surface of the groove 16 of the skin 15 and the slide plate 33 is smaller (that is, the center) at both ends U2 (in the illustrated example, the slope portion) than the center U1 in the length direction U of the slide plate 33. Since the gap S1> the gap S2 at both ends, the position where the ridge pattern 17 shown in FIG. 1 returns to the general shape becomes unstable, or the ridge pattern 17 undulates irregularly. Can be prevented.

  Thereafter, as shown in FIG. 13 to FIG. 15, the slide plate 33 is retracted in the course of foaming before the foaming raw material 19 a is completely foamed, and the slide plate 33 is extracted from the groove 16 of the skin 15. Since the foaming raw material 19a continues to foam and increases the pressure in the mold 30, the groove 16 is pressed to reduce the width of the groove 16, and a narrow groove pattern is formed on the surface of the skin 15. At the same time, the wrinkle pattern 17 shown in FIG. 1 is formed. The timing for removing the slide plate 33 from the groove 16 of the skin 15 is preferably the time when the foaming raw material 19a fills the periphery of the groove 16 of the skin 15. If the slide plate 33 is extracted from the groove 16 of the skin 15 at this timing, it is possible to prevent the occurrence of problems such as the groove 16 falling over due to the foaming pressure of the foaming raw material 19a.

  The foaming raw material 19a is filled between the skin 15 and the base material 11 by the progress of foaming, and becomes the foam 19 shown in FIG. The foam 19 is bonded and integrated with the skin 15 and the substrate 11 by the adhesiveness at the time of foaming. Thereafter, when the mold 30 is opened to remove the molded product, the skin-integrated foam 10 shown in FIGS. 1 and 2 is obtained. The skin-integrated foam 10 thus obtained has a highly decorative groove pattern in which the groove 16 of the skin 15 is narrowed. Furthermore, the skin-integrated foamed product 10 has a ridge pattern 17 formed at both ends of the groove 16, and has a higher decorativeness.

It is a perspective view which shows one Embodiment of the skin integrated foam which has a groove-like pattern in the surface manufactured by the manufacturing method of this invention. It is AA sectional drawing and BB sectional drawing of FIG. It is sectional drawing of the shaping | molding die used for one Embodiment of the manufacturing method of this invention. FIG. 4 is a partially enlarged sectional view of FIG. 3. It is CC sectional drawing of FIG. It is sectional drawing which shows the state which has arrange | positioned the skin on the mold surface in the same embodiment. It is a partial expanded sectional view of FIG. It is DD sectional drawing of FIG. It is sectional drawing which shows the time of foaming raw material injection | pouring in the same embodiment. It is sectional drawing which shows the middle of foaming in the same embodiment. It is a partial expanded sectional view of FIG. It is EE sectional drawing of FIG. It is sectional drawing which shows the state which extracted the slide plate from the groove | channel in the same embodiment. It is a partial expanded sectional view of FIG. It is FF sectional drawing of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Surface integrated foam which has a groove-like pattern on the surface 11 Base material 15 Skin 16 Groove 19 Foam 30 Mold 30 Lower mold 32 Lower mold surface 33 Slide plate 41 Upper mold 42 Upper mold surface

Claims (3)

In the method for producing a skin-integrated foam by placing a skin on the mold surface of the molding die, and injecting a foaming raw material into the molding die to cause foaming,
In the skin, a groove with a bottom recessed from the front surface side to the back surface side is provided in advance,
The mold is provided with a slide plate that can protrude and retract from the mold surface on which the groove of the skin is disposed,
In the state where the slide plate is inserted into the groove of the epidermis, the foaming raw material is allowed to foam,
A method of manufacturing a foam integrated with a skin having a groove-like pattern, wherein the slide plate is retracted and extracted from the groove of the skin before the foaming is completed.   The groove width is narrowed by pressing the groove of the skin with the foaming pressure of the foaming raw material by retracting the slide plate and extracting it from the groove of the skin before completion of the foaming. The manufacturing method of the skin-integrated foamed article which has the groove-shaped pattern of description. When the slide plate is inserted into the groove of the skin, a gap is formed between the tip of the slide plate and the bottom of the groove of the skin, and the slide at both ends rather than the center in the length direction of the slide plate The method for producing a foam integrated with a skin having a groove-like pattern according to claim 1 or 2, wherein a gap between the plate and the inner surface of the skin is made small.

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